Customer satisfaction is SIRUS fluid powers competitive edge. The maintenance and diagnostic team were asked to demonstrate there expertise by a local steel mill. The customer had failed to resolve a reoccurring intermittent hydraulic problem on the exit coil tilter. Following a meeting with the engineering manager we proposed to monitor the unit when the problem occurred and also look at the background of the system design. The coil lift cylinder would drop away when removing the coil. This problem had been within the circuit around 8 years. Given the background and the number of years the problem had been inherent. We proposed that our time would only be charged if we were successful in identifying and remedying the circuit. Failure to identify and remedy would result in no cost to the customer. After a few visits where we viewed the system, installed digital data logging equipment and analyzed the results we were confident in remedying the system during the next 12hour planned maintenance day. During the down period we removed various components from the system for inspection changed valves and made some minor pilot flow amendments. Since then the coiler tilt has never failed.

A leading oil refinery asked if we can assist by proposing a predictive maintenance program. The task was to monitor a number of radial piston motors with in a cooling system. The unit’s reliability was extremely poor and component failure was regular. The engineering team met the customer to discuss the background of the circuit and discuss the current maintenance program.

Due to the complex closed loop system we wrote a work program where digital data loggers were installed to monitor the working performance. The program proved a success as we were able to view the units working efficiency during production enabling us to view variable degrees of operating performance of each unit. The program enabled the customer to monitor and trend flow, pressure, rpm and fluid cleanliness. A program for system improvement and ongoing monitoring were proposed to the customer.

Using digital monitoring equipment we designed a predictive maintenance program to monitor the working efficiency of closed loop control valves. The objective was to reduce the failure rate when the units were removed for servicing as part of their preventative maintenance program.

The customer’s preventative maintenance was not suitable for the units as failure during commissioning was high. The engineering team met with the power station to discuss their requirements and the present maintenance procedures. The previous program was to remove each unit, refurbish and refit back into the system every 4 years; the units would then be tested when the power station was re-commissioned. Unfortunately there was a very high failure rate and extended delays. A new unit was sent to our workshop where we examined and engineered a control and monitoring circuit. A program of work was then proposed, where we would remove the valves and transport the units to Swansea where each unit would be powered and monitored. If the efficiency of the unit is within acceptable tolerances they were packed and sent back to be reinstated for another 4 years, failed units were stripped refurbished & retested before sending back.

All tests were recorded and actual data supplied as part of the certificate and report. As the time schedules were very tight, the above project proved to be a success.